Cap



Dec. l0,` 1968 C; BoNk ETAL 3,414,906

CAP

Filed Feb. 24, 1965 Vfpm j /GL INVENTOR CHA /M BOA/ff .5A/w 05A A Fon/frz TTORNI Y HG. 5 BY @eX/LM United States Patent C) 3,414,906 CAP ChaimBonk, 1916 Morgan Ave., and Samuel Rafowitz, 1922 Morgan Ave., both ofSt. Paul, Minn. 55116 Filed Feb. 24, 1965, Ser. No. 434,888 2 Claims.(Cl. 2-172) ABSTRACT OF THE DISCLOSURE A cap having a body portionterminating in a common plane along its lower edge. An annular flapadapted to encircle the head of a wearer is connected to the lower edgeof the cap by flexible tape wide enough to support the flap beneath theplane of the cap lower edge when in lowered position. The cap beingfoldable into the cap body when not in use. The flap is formed of twolayers of resilient woven material. Plastic foam material is laminatedto the inner surface of at least one of these layers.

This invention relates to an improvement in caps, and deals particularlywith a cap having an ear flap structure adapted to resiliently t thesides of a persons head when the ear flap structure is in the extendedposition.

It is an object of the present invention to provide means whereby theear flap structure when in the extended position will snugly encirclethe portions of a persons head.

It is a further object of the present invention to provide meansconnecting the ear flap structure to the cap body wherein the thicknessof the cap body with the ear ap structure folded into the body issubstantially the same from the lower edge of the body to the pointwhere the edge of the ear ap terminates.

While ear flaps have been known for a considerable period of time, twomajor disadvantages have consistently existed throughout the years. One,consisted of the greater thickness of the cap body along its terminaledge when the flap was folded inside the body. This tended to cause areduction in circulation, proved generally uncomfortable, and in manyinstances left a mark around the persons head. In the event that theperson purchased a cap which fitted snugly with the ear flap folded, thecap tended to t rather loosely when the ear iiaps were unfolded. As aresult, the purchaser was forced to decide whether he wanted a cap whichwould fit properly with the ear flaps up, or with the ear ilaps down.Second, a continuing fault has existed with ear aps in the unfolded ordownward position in that there normally was an opening or gap betweenthe persons head and the flaps adjacent the temple. As a result, coldair could enter along the sides of the head resulting in discomfort.

We have found that the bulkiness along the lower edge of the cap bodycould be overcome by providing a tape secured adjacent the lower edge ofthe cap body to which the ear flap structure was also secured. In otherwords, an elongated tape is secured along one longitudinal edge adjacentthe terminal edge of the cap body and secured along its otherlongitudinal edge to the ear flap structure. It will be understood thatgenerally the cap bodies are made in such a way that the outer coveringis turned inwardly and upwardly at its lower edge. If a single piece ofcloth is used, at the point where the cloth is folded inwardly andupwardly, the edge is then doubled in bulk. If, therefore, ear flaps aresecured to the cap body adjacent this lower terminal end, the bulk atthe lower terminal edge of the cap body includes the thickness of thefolded material, together with the thickness of the ear ap structure. Itis this particular bulkiness which the present application haseliminated.

As will be understood, by providing a tape of at least a lengthconforming to the length of the ear ap strucrice ture and of a widthsuiiicient to enable the ap structure to be folded inwardly above theends of the material forming the cap body, the bulkiness is avoided.

As will be understood further, we provide resilient means whereby theterminal edges of the downwardly extending ilap structure snuglyencircle the portions of the head to which they are adjacent. This isaccomplished by providing a resilient member of a length correspondinggenerally to the length of the terminal edge of the downwardly extendingflap. The resilient member urges the flap structure into contactingrelation along the sides of the head so as to avoid the problems whichhave been heretofore existent.

It is an object of the present invention to provide a cap having ear apstructure adapted to snugly t the head of a person having a resilientmember along the terminal edge of the flap structure whereby the apstructure is urged into contact with the head.

It is a further object of the present invention to provide an ear Hapstructure which may be used with a variety of cap structures includingat least those having a visor such as hunting caps and the like, andfurther including those which might be termed to be pillbox in shape.

lt is a further object of the present invention to provide an ear flapstructure which may be of varying widths and which may encircle at leastthe major portion of the cap body.

It is a further object of the present invention to provide ear ilapstructure connected to a cap body in which the ear ap structure may bemade of any suitable material, such as nylon, tricot, acetates, foamlaminated materials, and the like.

It is a further object of the present invention to provide a cap havingear flap structure which is attractive in appearance, and which is morecomfortable to wear than caps previously have been. Obviously, when theflap structure is folded upwardly to encircle the sides and otherinterior portions of the cap body, the cap is similar in appearance toany cap of the same general shape. At the same time, however, the capwhile tting the persons head with the flap structure folded upwardly,nevertheless, has the advantage of being capable of fitting the headsnugly when the flap structure is folded downwardly.

ln the preferred construction, the flexible resilient insert memberwhich extends along the terminal edge of the flap is enclosed inmaterial which corresponds to the rest of the flap. In other words, theap is similar in appearance throughout its length if desired, orobviously, contrasting materials and colors can be utilized to envelopthe 4resilient member of the terminal edge.

An important feature of the present invention resides in the facility ofthe flap to be made in different widths whereby it is possible to havethe flaps extend lower at the back and sides of the head, and to berelatively narrow adjacent the forehead. This is an obvious advantage,as it is usual that the portion of the head which is of greatestcircumference insofar as the cap is concerned, is usually located towardthe rear of the cap. As a result, the flap can be of sufficient lengthto cover the ears and lower portions of the head snugly, while at thesame time snugly encircling the forward portions of the head.

These and other objects and novel features of the present invention willbe more clearly and fully set forth in the following specification andclaims.

In the drawings forming a part of the specification:

FIGURE l is a perspective view of a conventional cap with the ear apsfolded downwardly.

FIGURE 2 is a side elevation of the cap shown in FIGURE l.

FIGURE 3 is a sectional View through a cap with the ear flap foldedupwardly.

FIGURE 4 is a section of the cap with the flaps in the lowered position.

FIGURE 5 is a section taken along the lines 5 5 of FIGURE 1.

FIGURE 6 is a section taken along the lines 6 6 of FIGURE 1.

The cap which is illustrated in the drawings is illustrative of thepreferred construction of the present invention.

The cap A includes a generally elongated teardrop shaped crown 10, whichmay be made of any desired material such as fabric, leather, imitationleather, laminates, nylons, tricot, acetates and the like.

The crown 10 is marginally secured by parallel rows of stitching 12 and14 to a depending skirt portion 16, which is generally elliptical inshape, and which extends throughout a major portion of the circumferenceof the crown. It is obvious that the crown together with the skirtdefines the depth of the cap body. If preferred, the generallycylindrical body portion of the cap can be formed in a substantiallyone-piece construction in the form of a pillbox.

The forward portion 18 of the cap body is secured along a seam generallynumbered 20 to a visor 22, which normally includes an upper layer, alower layer, and an intermediate stifener which is noted in FIGURE 5 ofthe drawings. An elongated tape 24 extends along the outer periphery ofthe visor 20 and is secured in desired relationship to the visor bystitching 26.

The remainder of the lower edge of the cap body is connected to an earmuff structure 28, which includes side members such as the flap 30. Ascan be seen in FIGURES 1 and 2, the ear muif structure might moreproperly be termed a warming band as in the preferred construction thisband 28 encircles the head. The band tapers in depth .l

at the forward end as indicated at 32. The forward end 32 is normallythe narrowest depth of the warming band, the band being of greater depthat the rear 34, and in the preferred construction of greatest depth atthe intermediate point 36 of the sides of the band.

The band may be of any desired material to conform or contrast with thecap body. For example, the band may be a knitted structure having foamlaminated thereon, where alternatively fur or other warm material may beused.

We have found that an extremely attractive warming band is provided byhaving two layers of knitted material to which foam is laminated securedtogether with the foam portions in face relation so as to have theknitted portions exposed. This provides warmth as well as an attractiveappearance. It will be understood that preferably the mui structure 28should be stretchable to some extent at least in longitudinal direction.Preferably, the muff or band is resilient in order to retain its shape.The mulf or band acts as a protector for the ears, back of the head andtemple portion of the head when the band is lowered, and are within thecap body when the flaps are raised.

As may be seen in FIGURES 1 and 2, the warming band is secured to thecap body by means of a tape 38. The connecting tape 38 extends inconnecting relation between the warming band and the lower edge 40 ofthe cap body. The tape 38 is of a length corresponding to the length ofthe warming band. The tape is in preferred construction folded in halfso as to be generally U-shaped throughout its length. The tape issecured along its upper edge to the cap body by stitching 42. Thewarming band is secured between the lower ends 44 and 46 of the tape bystitching 48.

Turning to FIGURE 3, it will be seen that in the usual cap construction,the terminal end 40 of the cap body is formed by folding over the endsof the material as indicated at 50. Accordingly, the terminal end 40 isof double thickness as compared to upper portions of the skirt. Thisdouble thicknessv provides a ridge of material which encircles the headand actually is the determinant of the cap size. In most caps, someeffort is made to eliminate this unsightly ridge by use of a liner ofsome type 0r another. The usual construction providing ear laps merelyincreases the bulk along this terminal edge, thereby even more tendingto reduce the diameter of the terminal edge as compared to the diameterof upper portions of the cap body. However, as may be seen in FIGURE 4,the tape 38 is secured in any desirable way, such as by stitching to thefolded terminal edge 40. At this point, the thickness of the terminaledge includes the folded skirt portion which makes up the terminal edgeand the upper edge of the tape 38. As may be seen in FIGURE 3, when thewarming band is folded into the interior of the cap body, the thicknessat the terminal edge corresponds to the thickness at the upper tape ends44 and 46, substantially to the other portions of the warming band aswell.

Turning again to FIGURE 4, we provide a resilient member 52, whichextends along the lower terminal end of the warming band 28. In thepreferred construction, this resilient member preferably includes aninsert 54, which is held in secured relation along the edge 56 of thewarming band by suitable stitching such as overlaid work whichcorresponds to the other portions of the band. The resilient member 52is adapted to stretch conformably to the shape of the head upon whichthe cap is worn and to snugly hold the warming band in engagementagainst the portions of the head. When the cap is removed from the head,the resilient member causes the band to return to its original shape. Inthe view pictured in FIGURE 4, the insert 54, is overlain by knitting soas to conform to the other portions of the band. Again, it is obviousthat contrasting colors may be used. The insert member may be ofrubber-like material and generally cylindrical outline, althoughobviously, resilient members of other suitable geometric shapes could beused equally as well. The shape of the resilient member will depend uponthe outline desired along the lower or terminal edge of the warmingband.

Turning again to FIGURE 3, it will be observed that the comparativethickness of the resilient member, together with the depending skirtagainst which it resides when the warming band is folded into the capbody, is substantially equal to the thickness at the terminal edge 40.In other words, we have provided a substantially uniform thicknessthroughout the interior of the cap by our construction.

As may be seen in FIGURE 6, a crown 10 is secured to the depending skirt16 along a seam line 58. To provide this seam 58, the edge 60 of thecrown is folded over and secured to a cooperable edge 62 by stitching64. The ends of the folded-over portions 60 and 62 are secured bygenerally parallel rows of stitching 14 and 12. In order to provide afinished appearance the tape 66 is in over lying relation to the turnededges 60 and 62, and secured by the rows of stitching 12 and 14.

In the event that a liner is used in the interior of the cap, the lineris secured in position under the tape 66.

The construction of the cap where the visor is secured to the front 18of the cap may be clearly seen in FIGURE 5. The terminal edge 68 of thecrown is folded over in a manner similar to other edges which have beenpreviously described. The upper and lower covering portions of the visor70 and 72 extend into overlying relation to the ter- -minal edge 68 ofthe crown, where they are held in stitched relation along the seam 20.

If desired, a sizing band may lbe used in addition. As will beunderstood, a sizing band would extend in encircling relation `along theinner lower terminal edge of the cap body to act as a stiffener endbacking, as well as to provide a definite sized relationship.

It will be observed in FIGURE 5, as in the preceding figures, that whenthe warming band is in a folded up* ward relation, that the thickness ofmaterial through the cap is substantially uniform. It will be furtherunderstood that as the connecting tape 38 is flexible, it will give inorder to provide the uniformity and positioned relationship `between thefolded edges of material.

It is a matter of importance that a variety of materials can be utilizedin a particular cap construction without depriving the user of thedesired advantages. While there are obvious advantages from thestandpoint of the user, from the standpoint of the manufacturer thereare even greater advantages. The manufacturer now, of course, can use avariety of materials in the same cap to provide even a greater range ofcolor and beauty, -as `well as usefulness.

Returning to FIGURES 1 and 2, it -will be observed that .as the 'bandhas stretchability and resilience, that the band will not tend to deformwhen on the head of the wearer and will return to its usual shape uponremoval from the head. In addition, this enables the band to snuglyengage not only at the rear of the head iin conformance to thatcurvature, but in addition, to snugly tit across the ears and upwardlytowards the temples. Obviously, the greatest stretch of the materialshould be along a front to back line as much as it is desired that theband hold its shape in an upward and downward direction as nearly aspossible, in order to provide the greatest coverage of the head Iwhenunfolded.

It is obvious, therefore, that the purchaser of the cap may purchase acap to t his head 4with the warming band folded inwardly and be assuredthat the cap will tit as desired, when the farming band is unfolded. Inaddition, the ypurchaser is assured that the warming band will fitsnugly around the head to prevent the former drafts which occurred fromentering along the sides of his head as in earlier construction.

In `accordance with the patent statutes, the principles of constructionand operation of this improvement in caps have been described, and whilewe have endeavored to set forth the best embodiment thereof, it shouldlbe understood that changes may be made within the scope of theaccompanying claims without departing from the spirit of the invention.

We claim:

1. A cap including:

a cap body having a crown, :and front, rear and side portions `connectedto the marginal edges of said crown and having a continuous inwardlyfolded lower edge with the fold thereof bein-g in a substantially commonplane,

an annular flap adapted to encircle the head of a wearer,

an annular tape having one longitudinal edge secured to, and inwardlyof, said inwardly' folded lower edge of said cap body, and having itsother longitudinal edge secured to the one edge of said Hap which isbelow the opposite edge of the said ap when the flap is `within said capbody,

said annular tape Vbeing of sufficient width to support sa'id one edgeof said ap to which it is secured below said common plane when said apis folded downwardly from said folded edge and the intermediate portionof said tape Ibetween said longitudinal edges thereof is adapted to foldbeneath the folded edge of said cap body when said cap is worn with theflap in lowered position,

an eongated longitudinally stretchable member extending along saidopposite edge of said flap which is uppermost when said flap is withinsaid cap body and lowermost when said flap is folded down out of saidcap body,

stretchable means enclosing said elongated lon-gitudinally stretchablemember and sercuring it to said opposite edge of said flap,

said flap being formed of two layers of resilient woven material and alayer of plastic foam material with at least one of said two layerslaminated to said plastic foam, the plastic foam being between saidlayers.

2. The structure of claim 1 and in which the other of said two layers ofresilient woven material is laminated to said plastic foam.

References Cited UNITED STATES PATENTS 1,379,142 5/1921 Wallace 2-1721,380,703 6/1921 Carlson 2-192 1,462,279 7/ 1923 Guinzburg 2 197 X2,462,258 2/1949 Dannenberg 2--172 2,717,394 9/1955 Portis 2-1722,885,683 5/1959 Lipkin 2-172 705,068 7/1902 Gordon 2-172 1,350,8698/1920 Kornfeld 2-172 2,634,725 4/1953 Lo Presti 2-174 X JORDANFRANKLIN, Primary Examiner.

G. KRIZMANICH, Assistant Examiner.

